System and method for providing three-dimensional features on large format print products

ABSTRACT

The invention provides a system and method for producing large format print products having three-dimensional features. The system incorporates at least one micro-dispensing jet valve and optionally a cutting apparatus to provide an integrated, efficient printing system capable of producing large format print products having dramatic three-dimensional features.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 17/062,569,filed Oct. 3, 2020, which claims the benefit of U.S. ProvisionalApplication No. 62/911,041, filed Oct. 4, 2019. The entire contents ofthese applications are incorporated herein by reference for allpurposes.

FIELD OF THE INVENTION

The invention generally relates to the printing industry. Moreparticularly, the invention relates to providing print products havingthree-dimensional features.

BACKGROUND

There exists a growing demand to increase the impact of large formatprint products by providing them with dramatic three-dimensionalfeatures, such as raised font, artistic features, glitter, and the like.Current market solutions for meeting this need suffer severallimitations. For example, existing inkjet print heads for providingthree-dimensional features must make several passes in order to achievea desired level of height and in an effort to produce dramaticthree-dimensional features. This compromises the efficiency of theprinting process and product output as more time is required to makemultiple printing passes. Another limitation of inkjet printer heads isthey are incapable of dispensing viscous materials which can providesignificantly raised three-dimensional features. Yet another limitationof existing inkjet systems for large format printing is that they do notallow three-dimensional features to be applied to pre-printed products.While the printing industry produces printed products withthree-dimensional features by hand, this process suffers the samelimitations of multiple-pass printing as it is inefficient and islimited in the quality of the three-dimensional features that itprovides.

Existing systems for providing print products with three-dimensionalfeatures are also deficient in that they are not configured to processlarge format print products, such as banners and signs. Additionally,large format printing systems lack an integrated cutting and creasingfunction. Thus, large format printed products made using these systemsmust be manually cut and creased, or cut and creased using a separatemachine, leading to a decrease in the efficiency and product output.

What is needed in the art therefore is a printing system and methodcapable of providing print products, including large format printproducts, with dramatic three-dimensional features in a single pass. Theart also needs a system and method that integrates a cutting andcreasing function in the processing of large format print jobs.

SUMMARY OF THE INVENTION

The invention overcomes the deficiencies of known three-dimensionalprinting devices and methods by providing a system comprising amicro-dispensing jet valve capable of efficiently producingthree-dimensional features in a single-pass print process. The systemand method can feature a cutting and creasing function for theintegrated processing of large-format print products.

A first object of the invention is to provide a system for making aprint product having at least one three-dimensional feature, comprising:a table adapted to receive a large format printable substrate; and atleast material dispensing module in operable communication with thetable in a manner that permits the material dispensing module todispense a material onto a large format printable substrate that isloaded onto the table.

In some aspects, the material dispensing module includes at least onemicro-dispensing jet valve.

In some aspects, the micro-dispensing jet valve is adapted to dispensedroplets that are between about 0.5 nl and about 5,000 nl in size.

In some aspects, the micro-dispensing jet valve is adapted to dispense amaterial having a viscosity of at least 150 millipascal seconds.

In some aspects, the micro-dispensing jet valve comprises a nozzle witha dispensing orifice that is between about 50 microns and about 600microns in diameter.

In some aspects, the material dispensing module comprises a heatingelement and at least one of a nozzle and a reservoir, wherein theheating element is adapted to heat at least one of the nozzle and thereservoir.

In some aspects, system comprises a plurality of material dispensingmodules.

In some aspects, the system further comprises a cutting tool, a creasingtool, a camera adapted to detect at least one registration mark on alarge format printable substrate, a UV curing module, or combinationsthereof.

In some aspects, the cutting tool is a blade, die, rotary knife, anglecutter, laser cutter, oscillating tool, or router.

In some aspects, the cutting tool is adapted to kiss cut a large formatprintable substrate.

In some aspects, the system further comprises a bridge, wherein thebridge is adapted to traverse at least a portion of the table and thebridge is connected to the at least one material dispensing module, thecutting tool, the creasing tool, the camera, the UV curing module, orcombinations thereof.

A second object of the invention is to provide a method of making alarge format print product having at least one three-dimensionalfeature, comprising: providing a system comprising at least one materialdispensing module; and providing a large format printable substrate;dispensing a material onto the large format printable substrate by thematerial dispensing module thereby providing a large format printproduct having at least one three-dimensional feature thereon.

In some aspects, the material permanently adheres to the large formatprintable substrate.

In some aspects, the material dispensing module includes at least onemicro-dispensing jet valve.

In some aspects, the micro-dispensing jet valve dispenses the materialas droplets that are between about 0.5 nl and about 5,000 nl in size.

In some aspects, the material is dispensed at a viscosity of at leastabout 150 millipascal seconds.

In some aspects, the micro-dispensing jet valve comprises a nozzlehaving dispensing orifice that is between about 50 microns and about 600microns in diameter.

In some aspects, the material dispensing module comprises a heatingelement and at least one of a nozzle and a reservoir, wherein theheating element heats at least one of the nozzle and the reservoir,thereby decreasing the viscosity of the material dispensed by thematerial dispensing module.

In some aspects, the system comprises a plurality of material dispensingmodules and the dispensing step comprises dispensing the same ordifferent materials onto the large format printable substrate by theplurality of material dispensing modules.

In some aspects, the system comprises a cutting tool and the system cutsthe large format printable substrate.

In some aspects, the system comprises a creasing tool and the creasingtool creases the large format printable substrate.

In some aspects, the material is selected from an adhesive, a UV curablematerial, or combination thereof.

In some aspects, the UV curable material is selected from a polyether, apolyurethane, an acryl, an epoxide, an epoxy, a silicone, a polyester,and combinations thereof.

In some aspects, the acryl is selected from an acrylic monomer, anacrylic oligomer, and combination thereof.

In some aspects, the acryl is selected from a monofunctional acryl, adifunctional acryl, a trifunctional acryl, a polyfunctional acryl, andcombinations thereof.

In some aspects, the material is combined with a reactive diluent, a UVsensitive photoinitiator, a rheology modifier, an epoxy catalyst, anadhesive, glitter, plastic particles, glass particles, metallicparticles, color pigment, phosphorescent powder, or combinationsthereof.

In some aspects, the material dispensing module dispenses a UV curablematerial onto the large format printable substrate, the system comprisesa UV curing module, and the UV curing module cures the dispensed UVcurable material.

In some aspects, the printable substrate is selected from fabric, foam,cardboard, paper, glass, fiberglass, plastic, corrugated carton, wood,metal, acrylic, pvc, vinyl, and combinations thereof.

In some aspects, the large format printable substrate has printed matterthereon and the material is dispensed onto at least a portion of theprinted matter thereby providing the portion with at least onethree-dimensional feature.

In some aspects, the three-dimensional feature includes at least onedomed feature.

In some aspects, the three-dimensional feature is between about 0.02inches to about 5 inches in height as measured from the surface of thelarge format print product.

A third object of the invention is to provide a system for making aprint product having at least one three-dimensional feature, comprising:a table adapted to receive a printable substrate and move the printablesubstrate along an x-axis with respect to the table; a bridge traversingthe table along a y-axis with respect to the table; a carriage connectedto the bridge, wherein the carriage is adapted to navigate the bridgeand comprises carriage elements including: a cutting tool; a cameraadapted to detect at least one registration mark on the printablesubstrate; a UV curing module; and a material dispensing module; and oneor more processors in electronic communication with one or more of thetable, the carriage, and at least one of the carriage elements; whereinat least one of the UV curing module and the material dispensing moduleare adapted to navigate a z-axis with respect to the table.

In some aspects, the table is adapted to receive a large formatprintable substrate.

In some aspects, the material dispensing module comprises at least oneof a nozzle, a reservoir, a heating element, and a controller, whereinthe element is adapted to heat at least one of the nozzle and thereservoir.

In some aspects, the carriage comprises a plurality of materialdispensing modules.

In some aspects, the material dispensing module is adapted to produce atleast one three-dimensional feature on the printable substrate.

In some aspects, the material dispensing module is adapted to produceone or more domed features on the printable substrate.

In some aspects, the material dispensing module is adapted to produce athree-dimensional feature on the print product that is between about0.02 inches to about 5 inches in height as measured from the surface ofthe print product.

In some aspects, the material dispensing module is a micro-dispensingjet valve.

In some aspects, the micro-dispensing jet valve is adapted to dispensedroplets having a size between about 0.5 nl and about 5000 nl.

In some aspects, micro-dispensing jet valve is adapted to dispense amaterial having a viscosity of at least 150 millipascal seconds.

In some aspects, the micro-dispensing jet valve comprises a nozzlehaving an orifice that is between about 50 microns and about 600 micronsin diameter.

In some aspects, the cutting tool is a blade, die, rotary knife, anglecutter, laser cutter, oscillating tool, or router.

In some aspects, the cutting tool is adapted to kiss cut the printablesubstrate.

In some aspects, the carriage elements include a creasing tool.

In some aspects, the material dispensing module is adapted to dispenseonto the printable substrate an adhesive, a UV curable material,glitter, glass particles, plastic particles, metallic particles, aphosphorescent powder, or combinations thereof.

In some aspects, the UV curable material is selected from a polyether, apolyurethane, an acryl, an epoxide, an epoxy, a silicone, a polyester,and combinations thereof.

In some aspects, the acryl is selected from an acrylic monomer, anacrylic oligomer, and combination thereof.

In some aspects, the acryl is selected from a monofunctional acryl, adifunctional acryl, a trifunctional acryl, a polyfunctional acryl, andcombinations thereof.

In some aspects, the UV curable material is combined with a reactivediluent, a UV sensitive photoinitiator, a rheology modifier, orcombinations thereof.

In some aspects, the system further comprises a computer readable mediumhaving a program thereon, wherein the program is adapted to read atleast one image file and permit the one or more processors to generateinstructions for the system to: (i) cut the printable substrateaccording to a cutting pattern, (ii) crease the printable substrateaccording to a creasing pattern, (iii) dispense a UV curable materialfrom the material dispensing module to produce at least onethree-dimensional feature on the printable substrate according to adispensing pattern; or (iv) combinations thereof.

In some aspects, the dispensing pattern includes instructions forilluminating the UV curable material with UV light by the UV curingmodule as the UV curable material dispensing module dispenses the UVcurable material.

In some aspects, the table comprises a belt or rollers that are adaptedto move the printable substrate along the x-axis of the table.

A fourth object of the invention is to provide a method of making aprint product having at least one three-dimensional feature, comprising:providing a system comprising: (i) a table adapted to receive aprintable substrate and move the printable substrate along an x-axiswith respect to the table; (ii) a bridge traversing the table along ay-axis with respect to the table; (iii) a carriage adapted to navigatethe bridge, wherein the carriage is connected to a cutting tool, acamera, a UV curing module, and at least one material dispensing modulewherein at least one of the material dispensing module and the UV curingmodule are adapted to navigate a z-axis with respect to the table; and(iv) a processor; placing on the table a printable substrate having atleast one registration mark; and executing instructions by the processorto: (i) move the printable substrate by the table along the x-axis andmove the carriage on the bridge along the y-axis thereby permitting thecamera to detect the registration mark; (ii) cut the printable substrateby the cutting tool according to a first pattern and the registrationmark; (iii) dispense a first one or more layers of at least one UVcurable material onto the printable substrate by the material dispensingmodule according to a second pattern and the registration mark; and (iv)illuminate the first one or more layers of the dispensed UV curablematerial with UV light by the UV curing module; wherein executing theinstructions provides a print product that is cut according to the firstpattern and has at least one three-dimensional feature according to thesecond pattern.

In some aspects, the printable substrate is a large format printablesubstrate.

In some aspects, executing the instructions (i) moves at least one ofthe material dispensing module and the curing module along the z-axis,(ii) dispenses a second one or more layers of the UV curable material bythe material dispensing module, and (iii) illuminates the second one ormore layers by the curing module.

In some aspects, the material dispensing module comprises a heatingelement and at least one of nozzle and a reservoir, wherein the heatingelement is adapted to heat at least one of the nozzle and the reservoir.

In some aspects, the carriage is connected to a plurality of materialdispensing modules.

In some aspects, the material dispensing module is a micro-dispensingjet valve.

In some aspects, the micro-dispensing jet valve dispenses the UV curablematerial in droplets having a size of between about 0.5 nl and about5000 nl.

In some aspects, the dispensed UV curable material has a viscosity of atleast 150 millipascal seconds.

In some aspects, the micro-dispensing jet valve comprises a nozzle withan orifice between about 50 microns and about 600 microns in diameter.

In some aspects, the cutting tool is a blade, die, rotary knife, anglecutter, laser cutter, oscillating tool, or router.

In some aspects, the cutting tool produces a kiss cut on the printablesubstrate.

In some aspects, the system further comprises a creasing tool andexecuting the instructions includes executing instructions to crease theprintable substrate by the creasing tool.

In some aspects, the three-dimensional feature includes one or moredomed features.

In some aspects, the three-dimensional feature has a height betweenabout 0.02 inches to about 5 inches as measured from the surface of theprintable substrate.

In some aspects, the system comprises a plurality of material dispensingmodules, and dispensing the first one or more layers comprisesdispensing a plurality of UV curable materials.

In some aspects, the UV curable material is combined with an adhesive,glitter, plastic particles, glass particles, metallic particles, colorpigment, phosphorescent powder, or combinations thereof.

In some aspects, the UV curable material is selected from a polyether, apolyurethane, an acryl, an epoxide, an epoxy, a silicone, a polyester,and combinations thereof.

In some aspects, the acryl is selected from an acrylic monomer, anacrylic oligomer, or combination thereof.

In some aspects, the acryl is selected from a monofunctional acryl, adifunctional acryl, a trifunctional acryl, a polyfunctional acryl, orcombinations thereof.

In some aspects, the UV curable material is combined with a reactivediluent, a UV sensitive photoinitiator, a rheology modifier, orcombinations thereof.

In some aspects, the UV curing module illuminates the UV curablematerial as the UV curable material is dispensed by the materialdispensing module.

In some aspects, the table comprises a conveyor belt or rollers and theprintable substrate is moved along the x-axis by the conveyor belt orthe rollers.

In some aspects, printable substrate has printed matter thereon and thematerial dispensing module dispenses the UV curable material onto atleast a portion of the printed matter thereby providing the portion withat least one three-dimensional feature.

In some aspects, the instructions are obtained from a computer readablemedium that is accessed by the system.

These and other objects of the invention will be apparent to one skilledin the art in view of the following disclosure. The drawings andspecific descriptions of the drawings, as well as any specific oralternative embodiments discussed, are intended to be read inconjunction with the entirety of this disclosure. The inventive systemand method may, however, be embodied in many different forms and shouldnot be construed as being limited to the embodiments set forth herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an embodiment of the printing system ofthe invention.

FIG. 2 is a schematic diagram of carriage elements of an embodiment ofthe printing system of the invention.

FIG. 3 is a schematic diagram of a material dispensing module of thesystem of the invention including associated components.

FIG. 4 is a flow chart of a process of the invention.

DEFINITIONS

As used herein, the term “about” means the quantity, level, value,number, frequency, percentage, dimension, size, amount, weight or lengththat is referenced, or that varies (plus or minus) by as much as 30%,25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2% or 1% of thereferenced quantity, level, value, number, frequency, percentage,dimension, size, amount, weight or length.

As used herein, the phrase “large format print product” refers to aprintable media having a length, width, circumference, or otherdimension that is at least 18 inches and which printable has beenprocessed according to the system or method of the invention.

As used herein, the phrase “large format printable substrate” refers toa printable media having a length, width, circumference, or otherdimension that is at least 18 inches and which printable media is actedupon by the system and method of the invention.

As used herein, the phrases “permanently adhere,” “permanently adhered,”and the like, can refer to a connection between two substances (e.g. aprintable substrate and three-dimensional feature thereon) that cannotbe broken by physical force without damaging the physical integrity ofeither substance, such as damage in the nature of tearing, cracking,denting, or shattering.

DETAILED DESCRIPTION

The invention generally relates to a system and method for providingthree-dimensional features on print products. More particularly, theinvention provides a system and method featuring a micro-dispensing jetvalve adapted to dispense a material in a manner that providessignificantly raised three-dimensional features on print products,including, without limitation, large format print products. The systemcan optionally include at least one of a cutting function and a creasingfunction to provide an integrated printing process.

FIG. 1 is a schematic diagram of a non-limiting embodiment of theprinting system of the invention. The system features table 40 which isadapted to receive a printable substrate and traversed by bridge 10. Insome aspects, table 40 is a digital flatbed cutter. Bridge 10 isoperably connected to carriage 20 in a manner that permits carriage 20to navigate at least a portion of the length of bridge 10 such thatcarriage 20 moves over the surface of table 40 along a y-axis withrespect to table 40. Carriage 20 is adapted to house one or morecarriage elements as disclosed herein. Bridge 10 can be connected totable 40, or comprise a separate frame configured to hold bridge 10 overtable 40 in a manner that permits carriage 20 to move over the surfaceof table 40. Table 40 can comprise a roll feeder or conveyor beltassembly that is configured to move a printable substrate along anx-axis with respect table 40. Table 40 can be a cutter or flatbedplotter. Suitable plotters for use with the invention include, but arenot limited to, a Zund plotter manufactured by Zund Systemechnik AG™, aWild™ plotter, or Esko Kongsberg™ plotter, for example.

FIG. 2 is a schematic drawing of bridge 10 in mechanical connection withcarriage 20. Carriage 20 is connected to bridge 10 in a manner thatpermits carriage 10 to navigate bridge 10 along a longitudinal axis ofbridge 10 under the power of an electronic motor, for example, which canbe housed within bridge 10 carriage 20. In other aspects, carriage 20 isin mechanical communication with a motor housed externally from bridge10 and carriage 20, wherein carriage 20 is in mechanical communicationwith the motor through belts and pulleys adapted to move carriage 20along the longitudinal axis of bridge 10. Table 40 and bridge 10 canassume the configuration of the apparatus disclosed in U.S. PublicationNo. 2005/0247173, the entire contents of which are incorporated hereinby reference for all purposes. In some aspects of the invention, table40 is adapted to receive a large format printable substrate. Forexample, table 40 can be of a size that is sufficient to support atleast a portion of a large format printable substrate while the largeformat printable substrate is acted upon, or in accordance with, thesystem and method of the invention.

Carriage 20 can be connected to one or more carriage elements selectedfrom creasing tool 31, camera 32, cutting tool 33, material dispensingmodule 34, curing module 35, and z-axis mechanism 36. In at least oneaspect of the invention, carriage 20 is connected to each of camera 32,cutting tool 33, material dispensing module 34, curing module 35, z-axismechanism 36, and optionally creasing tool 31. Carriage 20 can beconnected to two, three, four, five, or more material dispensingmodules. Camera 32 is configured to detect one or more registrationmarks on a printable substrate and communicate with a system processorto permit the processor to instruct one or more of the remainingcarriage elements to perform their respective functions according to apredetermined print product configuration. For example, the systemprocessor can instruct material dispensing module 34 to deposit amaterial (e.g. a UV curable material) on the printable substrate basedon camera 32's detection of at least one registration mark on theprintable substrate. Camera 32 can be a sensor adapted to read one ormore registration marks on a printable substrate. In at least onenon-limiting embodiment, camera 32 is a CCD camera. The system processorcan instruct cutting tool 33 to cut the printable substrate according toa pre-determined pattern to produce a printed product having a desiredshape or configuration. As will be appreciated by one skilled in theart, UV curing module 35 can be an ultraviolet light source configuredto generate an amount of ultraviolet light sufficient to cure a UVcurable material that is deposited on a printable substrate by materialdispensing module 34. Cutting tool 33 is adapted to cut a printablesubstrate to produce a finished print product having a desired shape orconfiguration. Suitable cutting tools for use with the invention,include, but are not limited to, blades, dies, rotary knives, anglecutters, laser cutters, oscillating tools, and routers. In someembodiments of the invention, the cutting tool is adapted to kiss-cutthe printable substrate. Cutting tools for use with the invention can bethose systems provided by Zund Cutting Industries™, for example. Z-axismechanism 36 is adapted to move at least one of material dispensingmodule 34 and UV curing module 36 towards and away from table 40 along az-axis with respect table 40. Z-axis mechanism 36 can comprise acontroller and motor which are configured to raise and lower materialdispensing module 34 (or component thereof) so as to permit the moduleto dispense a material to achieve a desired height for thethree-dimensional feature that is desired, or to achieve a desired levelof resolution. For example, z-axis mechanism 36 can move dispensing head34.1, nozzle 34.2, heating element 34.6, and UV curing module 35 awayfrom the surface of a printable substrate so as to permit the system toapply and cure multiple layers of a UV curable material without thelayers contacting nozzle 34.2.

In some embodiments of the invention, material dispensing module 34 is anon-contact micro-dispensing jet valve. The micro-dispensing jet valvecan be adapted to dispense droplets of material in a size between about0.5 nl and about 5,000 nl. The micro-dispensing jet valve can be adaptedto dispense a high viscosity material. By dispensing high viscositymaterials, the micro-dispensing jet valve permits the system to provideprint products having significantly raised three-dimensional features.The micro-dispensing jet valve for use with the system and methoddisclosed herein can be adapted to dispense materials having a viscosityof at least about 150 millipascal seconds, at least about 200millipascal seconds, at least about 250 millipascal seconds, at leastabout 300 millipascal seconds, at least about 350 millipascal seconds,at least about 400 millipascal seconds, at least about 450 millipascalseconds, or at least about 500 millipascal seconds. In some aspects, themicro-dispensing jet valve for use with the system and method disclosedherein is adapted to dispense materials having a viscosity that isbetween about 150 millipascal seconds and about 5,000 millipascalseconds, between about 200 millipascal seconds and about 5,000millipascal seconds, between about 250 millipascal seconds and about5,000 millipascal seconds, between about 300 millipascal seconds andabout 5,000 millipascal seconds, between about 350 millipascal secondsand about 5,000 millipascal seconds, between about 400 millipascalseconds and about 5,000 millipascal seconds, between about 450millipascal seconds and about 5,000 millipascal seconds, between about500 millipascal seconds and about 5,000 millipascal seconds, betweenabout 1,000 millipascal seconds and about 5,000 millipascal seconds,between about 1,500 millipascal seconds and about 5,000 millipascalseconds, between about 2,000 millipascal seconds and about 5,000millipascal seconds, between about 2,500 millipascal seconds and about5,000 millipascal seconds, between about 3,000 millipascal seconds andabout millipascal seconds, between about 3,500 millipascal seconds andabout 5,000 millipascal seconds, between about 4,000 millipascal secondsand about 5,000 millipascal seconds, or between about 4,500 millipascalseconds and about 5,000 millipascal seconds.

Suitable micro-dispensing jet valves for use with the invention include,but are not limited to, a modular PICO Pμlse Jet Valve™ configurationavailable from Nordson EFD™. In other aspects, the micro-dispensing jetvalve can be micro-dispensing system Model No. MDS 3280 or MDS 1560 fromVermes Microdispensing™. The micro-dispensing jet valve can be thedevice disclosed in US Patent Application Publication No. 2014/0291358,or the dispenser disclosed in U.S. Pat. No. 7,694,855, the entirecontents of which are incorporated herein by reference for all purposes.

FIG. 3 is a schematic drawing showing a non-limiting embodiment of amaterial dispensing module and associated components for use with theinvention. The material dispensing module can be a micro-dispensing jetvalve connected to dispensing head 34.1 having a valve therein andconnected to nozzle 34.2. Nozzle 34.2 can have a dispensing orifice thatis between about 50 microns and about 600 microns in diameter. Nozzle34.2 can have an orifice diameter that is about 50 microns, about 100microns, about 150 microns, about 200 microns, about 250 microns, about300 microns, about 350 microns, about 400 microns, about 450 microns,about 500 microns, about 550 microns, or about 600 microns. Dispensinghead 34.1 and nozzle 34.2 are in fluid communication with reservoir 34.3through feed line 34.7. In some embodiments, dispensing head 34.1 andnozzle 34.2 are connected to heating element 34.6 which is adapted toheat a material from feed line 34.7 to achieve a desired level ofviscosity for dispensed material 101 which is deposited on printablesubstrate 100. Dispensing head 34.1 can be in electronic communicationwith controller 34.4 which is adapted to control the opening and closingof the valve within dispensing head 34.1 so as to regulate the open andclose time of the valve and thus regulate at least one of the dispensingrate and drop size of dispensed material 101. Controller 34.4 can be inelectronic communication with heating element 34.6 to control thetemperature of dispensing head 34.1 and nozzle 34.2, thereby regulatingthe temperature and viscosity of dispensed material 101. As disclosedherein, material dispensing module 34 (including dispensing head 34.1and nozzle 34.2) and UV curing module 35 can be in mechanicalcommunication with z-axis mechanism 36 to permit z-axis mechanism 36 tomove dispensing module 34 and UV curing module 35 toward and away fromprintable substrate 100.

Reservoir 34.3 is adapted to contain a material that is dispensed ontoprintable substrate 100 as depicted by dispensed material 101. Reservoir34.3 can be adapted to contain a UV curable material. The UV curablematerial can have a high viscosity (e.g. greater than about 150millipascal seconds). The reservoir can be a reservoir produced byFisnar™, including, without limitation, the following model numbers:IJ2601 N-55-SP; IJ2601 N-55; IJ-0100; IJ-01 OOR; IJ-0200; IJ-0200R;IJ-0300; IJ-0300R; IJ-832-211; IJ-83B-500; IJ-838-500-SP; IJ-838-500-BK;IJ-83G-510-SP; FT1; FT1-AG; FT2; FT2-AG; FT5; FT5-AG; FT10; and FT10-AG.The features and specifications of these reservoirs are incorporatedherein by reference for all purposes. Reservoir 34.3 can be incommunication with a means for producing pressure in the reservoir, suchas a compressor or source of compressed gas via pressure line 34.5.Pressure line 34.5 can include an in-line pressure regulator that isadapted to regulate the pressure within reservoir 34.3. Whenpressurized, reservoir 34.3 supplies a material for dispensing todispensing head 34.1 though feed line 34.7. In at least one alternativeembodiment, reservoir 34.3 is in fluid communication with a pump thatsupplies a material for dispensing to dispensing head 34.1 through feedline 34.7.

Material dispensing module 34 can be associated with UV curing module 35which is adapted to polymerize a UV curable material dispensed throughnozzle 34.2. In some embodiments, at least one of dispensing head 34.1,nozzle 34.2, heating element 34.6, and UV curing module 35 aremechanically connected to z-axis mechanism 36 so as to permit z-axismechanism 36 to move at least one of dispensing head 34.1, nozzle 34.2,heating element 34.6, and UV curing module 35 toward and away fromprintable substrate 100 during the printing process in order to permitthe device to provide a desired height or resolution for thethree-dimensional feature being provided on printable substrate 100. Itwill be understood that z-axis mechanism can be in mechanicalcommunication with a power means, such as a motor or solenoid, to powerthe movement of the dispensing head 34.1, nozzle 34.2, heating element34.6, and UV curing module 35 toward and away from printable substrate100.

In at least one embodiment, the invention provides a method of providinga print product having at least one three-dimensional feature thereon.The method can be practiced by providing a material dispensing module,providing a printable substrate, dispensing a UV curable material onto asurface of the printable substrate using the material dispensing module,and curing the dispensed UV curable material with ultraviolet light,wherein curing the dispensed UV curable material produces at least onethree-dimensional feature that is permanently adhered to the printablesubstrate thereby providing a print product having at least onethree-dimensional feature. The material dispensing module can be amicro-dispensing jet valve as disclosed herein. Curing the UV curablematerial can be accomplished by an ultraviolet light source. The methodof this embodiment can be performed using a system as disclosed herein.

In some embodiments of the method, the material dispensing moduledispenses a material that is an adhesive that is then contacted with atexture providing material, such as glitter, glass, plastic, or metallicparticles (e.g. colored glass, colored metallic, or colored plasticparticles), or a phosphorescent powder, for example. In some aspects,the material dispensing module dispenses the adhesive and textureproviding material as a mixture. The adhesive can be an adhesive that iscured without the application of ultraviolet light, such as by exposureto air, for example.

In some embodiments, the dispensing and curing steps are performedsimultaneously. The dispensing and curing steps can be performedsimultaneously in one, two, three, four, five or more applications. Forexample, the method can comprise a first application wherein the UVcurable material is dispensed and cured in a first application, and thedispensing and curing steps are repeated over the previously dispensedand cured UV curable material thereby providing a three-dimensionalfeature comprising a plurality of layers. In other embodiments, the UVcurable material is dispensed in multiple layers and then cured withultraviolet light to provide a three-dimensional feature comprising aplurality of layers.

The method and system of the invention can be used to providethree-dimensional features on a wide range of printable substrates. Theprintable substrate can be a flat, planar object or medium. Theprintable substrate for use with the invention can be a materialselected from fabric (e.g. cloth and canvas), foam, cardboard, paper,glass, fiberglass, plastic, corrugated carton, wood, metal (e.g.aluminum), acrylic, vinyl (e.g. PVC, PP, and PET), and combinationsthereof. In some aspects of the invention, the printable substrate is alarge format print product. Non-limiting examples of large format printproducts include, but are not limited to: wrappings; boxes, bags, andother packaging; decals and magnets for vehicles (e.g. cars, trucks,buses, SUVs, and vans); wrappings for vending machines and light boxes;wall and window decals and coverings; window blinds; canvas prints andpaintings; t-shirts; flags; signs (e.g. yard signs and billboards);banners; posters; point of sale displays; cut-outs; curtains; sofacovers; table cloths; wood furniture; and wood decorations. In someaspects, the system and method are used to provide three-dimensionalfeatures on a non-large format printed product, such as, for example,keychains, business cards, pins, decals, letterhead, envelopes, phonecases, and promotional articles.

In some aspects of the invention, the printable substrate is pre-printedwith printed matter such as text, designs, or images, for example. Insome aspects of the invention, at least a portion of the printed matteris used as registration marks which are used as paths for cutting,creasing, and/or dispensing a UV curable material and/or adhesive. Thesystem and method of the invention can provide printed matter with athree-dimensional effect by overlaying at least a portion of the printedmatter with a UV curable material and/or adhesive by a materialdispensing module as disclosed herein.

At least one aspect of the invention concerns the three-dimensionalfeatures that are provided on the surface of the printable substrate bythe system and method of the invention. The three-dimensional featurecan be a raised from the surface of the printable substrate and have aheight of between about 0.02 inches to about 5 inches as measured fromthe top of the three-dimensional feature to the surface of the printablesubstrate upon which a UV curable material and/or adhesive is applied.The three-dimensional feature can assume the form of images, designs,shapes, text, brail, or doming, for example. In some aspects of theinvention, the three-dimensional feature comprises a plurality of domesthat are selectively located on a surface of the printable substrate, ora single dome that covers all or a majority of a surface of theprintable substrate. The three-dimensional feature can optionally beoverlaid on matter that is pre-printed on a printable substrate.

In some aspects of the invention, the system and method dispense a UVcurable material onto a printable substrate. The UV curable material canbe a material having sufficient viscosity to remain raised after beingdispensed on the printable substrate such that curing the dispensed UVcurable material produces a three-dimensional feature on the printablesubstrate. The UV curable material can have a dispensing viscosity of atleast about 150 millipascal seconds, at least about 200 millipascalseconds, at least about 250 millipascal seconds, at least about 300millipascal seconds, at least about 350 millipascal seconds, at leastabout 400 millipascal seconds, at least about 450 millipascal seconds,or at least about 500 millipascal seconds. In some aspects, the UVcurable material has a viscosity that is between about 150 millipascalseconds and about 5,000 millipascal seconds, between about 200millipascal seconds and about 5,000 millipascal seconds, between about250 millipascal seconds and about 5,000 millipascal seconds, betweenabout 300 millipascal seconds and about 5,000 millipascal seconds,between about 350 millipascal seconds and about 5,000 millipascalseconds, between about 400 millipascal seconds and about 5,000millipascal seconds, between about 450 millipascal seconds and about5,000 millipascal seconds, between about 500 millipascal seconds andabout 5,000 millipascal seconds, between about 1,000 millipascal secondsand about 5,000 millipascal seconds, between about 1,500 millipascalseconds and about 5,000 millipascal seconds, between about 2,000millipascal seconds and about 5,000 millipascal seconds, between about2,500 millipascal seconds and about 5,000 millipascal seconds, betweenabout 3,000 millipascal seconds and about 5,000 millipascal seconds,between about 3,500 millipascal seconds and about 5,000 millipascalseconds, between about 4,000 millipascal seconds and about 5,000millipascal seconds, or between about 4,500 millipascal seconds andabout 5,000 millipascal seconds. In some aspects, the UV curablematerial is heated by the micro-dispensing jet valve nozzle, head,reservoir, or combination thereof, to achieve the viscosities disclosedherein. The UV curable material can be combined with a rheology modifierto achieve the viscosities disclosed herein.

The UV curable material can comprise any material known in the art thatis capable of being cured by UV-light to permanently adhere to thesurface of a printable substrate to which the material is applied.Non-limiting examples of the UV curable material include, but are notlimited to, polyethers, polyurethanes, acryls, epoxides, epoxies,silicones, polyesters, or combinations thereof. The UV curable materialcan be an acrylate monomer with one, two, three or more acrylic group.The UV curable material can be an acrylate oligomer, such as an epoxyacrylate or a urethane acrylate, or an aliphatic urethane acrylate, forexample. The UV curable material can be combined with a curableoligomer, a reactive diluent, a curing agent, an epoxy catalyst, a UVsensitive photoinitiator, an amine synergist, a rheology modifier, aperformance improving additive, or combinations thereof. Non-limitingexamples of these materials are disclosed in U.S. Pat. No. 9,216,543,the entire contents of which are incorporated herein by reference forall purposes. The UV curable material can be an aliphatic urethaneacrylate, such as, for example, Catalog No. UV 60-7180 or Catalog No. UV60-7185 available from Epoxies Etc., Inc.

The UV curable material can be colored and opaque or clear. For example,the UV curable material can be mixed with color pigments, including,without limitation, metallic pigments. The UV curable material can becombined with particles to enhance the three-dimensional effects ofmaterial. For example, the UV curable material can be combined withglitter, glass particles, metallic particles, or plastic particles (e.g.colored glass, metallic, or plastic particles), or a phosphorescentpowder. The UV curable material can be combined with an adhesive. Insome embodiments, the method of the invention comprises cutting a printproduct. Such cutting can take place before or after a three-dimensionalfeature is provided onto the printable substrate. The print product canbe cut by means of a blade, die, rotary knife, angle cutter, lasercutter, oscillating tool, or router. Cutting the print product cancomprise cutting a large format print product using a system asdisclosed herein.

FIG. 4 is flow chart of the steps of a non-limiting embodiment of amethod of using a system of the invention to produce a print producthaving one or more three-dimensional features. The method begins with areceiving step wherein a computer file encoding a desired print productis uploaded to the system of the invention. The computer file canprovide the dimensions for the print product, the three-dimensionalfeatures that are desired, and optionally a creasing configuration forthe product. A processor within the system reads the file and createsone or more cut paths, and optionally one or more crease paths, by whichthe print product will be cut and optionally creased. The processor thencreates a path (i.e. doming path) by which a UV curable material (and/oradhesive) will be dispensed to provide a desired one or morethree-dimensional features on the print product. The processor thencreates and identifies one or more image registration marks to be usedto guide the cutting, dispensing, and optional creasing steps to beperformed by the system. The file is then read to execute instructionsto print printed matter onto a printable substrate to provide a printedmedia. In some aspects, the printed matter is printed onto the printablesubstrate via an external print system. The printable substrate is thenprocessed by the system of the invention whereupon the system cuts theprinted media, optionally creases the printed media according to thepaths created by the processor in the preceding steps. The system of theinvention then dispenses and cures a UV curable material (i.e. domingmaterial) on a surface of the printable substrate thereby providing aprint product having at least one three-dimensional feature and adesired product configuration.

A non-limiting embodiment of the method of the invention is practiced byproviding a system comprising (i) a table adapted to receive and move aprint product along an x-axis with respect to said table, (ii) a bridgetraversing the table along a y-axis with respect to said table, (iii) acarriage adapted to navigate the bridge, wherein the carriage isconnected to one or more carriage elements that include a cutting tool,a camera, a UV curing module, and at least one material dispensingmodule, and (iv) a processor adapted to read an image file and executeinstruction to operate the components of the system. A printablesubstrate having at least one registration mark is then placed on thetable, after which the processor executes instructions to activate thetable to move the printable substrate along the table, and move thecarriage along the bridge, so as to permit the camera to detectregistration marks on the printable substrate and provide feedback tothe processor to permit the processor to determine the position of thecarriage elements. Upon determining the position the carriage elementsrelative to the printable substrate, the processor reads the image filefor the desired print product configuration and executes (v)instructions to the material dispensing module to dispense a UV curablematerial onto the upward facing surface of the printable substrateaccording to the image file, and (vi) instructions to the UV-curingmodule to illuminate the dispensed material with ultraviolet light so asto cure the material such that the dispensed material permanentlyadheres to the printable substrate to provide a print product having oneor more three-dimensional features on the printable substrate's upwardfacing surface. In some aspects, the printable substrate containsprinted matter on its surface and the UV curable material is dispensedon at least a portion of the printed matter. The processor can thenexecute instructions to move the print product on the table, and thecarriage along the bridge, to permit the camera to detect registrationmarks and provide feedback to the processor regarding the position ofthe cutting tool whereupon the cutting tool executes instructions to thecutting tool to cut the print product according to the image file. Insome embodiments of the method, the dispensing and curing steps areperformed after the cutting steps. It will be understood that thematerial dispensing module can be a micro-dispensing jet valve asdisclosed herein. It will further be understood that the print productcan be a large format print product.

Different features, variations and multiple different embodiments havebeen shown and described with various details. What has been describedin this application at times in terms of specific embodiments is donefor illustrative purposes only and without the intent to limit orsuggest that what has been conceived is only one particular embodimentor specific embodiments. It is to be understood that this disclosure isnot limited to any single specific embodiments or enumerated variations.Many modifications, variations and other embodiments will come to mindof those skilled in the art, and which are intended to be and are infact covered by both this disclosure. It is indeed intended that thescope of this disclosure should be determined by a proper legalinterpretation and construction of the disclosure, includingequivalents, as understood by those of skill in the art relying upon thecomplete disclosure present at the time of filing.

REFERENCE CHARACTERS

-   -   10—Bridge    -   20—Carriage    -   40—Table    -   31—Creasing tool    -   32—Camera    -   33—Cutting tool    -   34—Material dispensing module    -   34.1—Dispensing head    -   34.2—Dispensing module nozzle    -   34.3—Reservoir    -   34.4—Controller    -   34.5—Pressure unit    -   34.6—Heating element    -   34.7—Feed line    -   35—UV curing module    -   36—Z-axis mechanism    -   100—Substrate    -   101—Dispensed material

1. A system for making a print product having at least one three-dimensional feature, comprising: a) a table adapted to receive a large format printable substrate; and b) at least one material dispensing module in operable communication with said table in a manner that permits said material dispensing module to dispense a material onto a large format printable substrate that is loaded onto said table.
 2. The system of claim 1, wherein said at least one material dispensing module includes at least one micro-dispensing jet valve.
 3. The system of claim 2, wherein said at least one micro-dispensing jet valve is adapted to dispense droplets that are between about 0.5 nl and about 5,000 nl in size.
 4. The system of claim 2, wherein said at least one micro-dispensing jet valve is adapted to dispense a material having a viscosity of at least 150 millipascal seconds.
 5. The system of claim 2, wherein said at least one micro-dispensing jet valve comprises a nozzle with an orifice that is between about 50 microns and about 600 microns in diameter.
 6. The system of claim 1, wherein said at least one material dispensing module comprises a heating element and at least one of a nozzle and a reservoir, wherein said heating element is adapted to heat at least one of said nozzle and said reservoir.
 7. The system of claim 1, wherein said system comprises a plurality of material dispensing modules.
 8. The system of claim 1, wherein said system further comprises a cutting tool, a creasing tool, a camera adapted to detect at least one registration mark on a large format printable substrate, a UV curing module, or combinations thereof.
 9. The system of claim 8, wherein said cutting tool is a blade, die, rotary knife, angle cutter, laser cutter, oscillating tool, or router.
 10. The system of claim 8, wherein said cutting tool is adapted to kiss cut a large format printable substrate.
 11. The system of claim 8, further comprising a bridge, wherein said bridge is adapted to traverse at least a portion of said table and said bridge is in operable communication with at least one of said material dispensing module, said cutting tool, said creasing tool, said camera, and said UV curing. 